fireclad system boral

PB215June 2005

2 June 2005 Boral FireCLAD®

IntroductionIndustrial Building Designers and their designs need no longer be limited when considering fire-resistant materials and their components. The Boral Plasterboard FireCLAD® System, developed in conjunction with BlueScope Steel is a cost and time efficient method of providing the required fire rating to external walls of new and existing steel framed construction as an alternative to precast concrete or masonry. The Boral Plasterboard FireCLAD® System provides fire resistant industrial exterior walls, where they are necessary, due to the nearness of neighbouring properties or proximity of one building to another.

Apart from any necessary internal fire resistance, the Building Code of Australia (BCA) requires one and two-storey storage buildings, car parks, laboratories, factories and workshops to have fire resistant external walls where the building is within three (3) metres of a property boundary or another building. These external walls must have 60 minutes fire resistance to external fire attack. Where the distance from the boundary or adjoining building is less than 1.5 metres, the fire resistance level required is increased to 90 minutes. The Boral Plasterboard FireCLAD® System may also be used in other building types where fire resistance of up to 120 minutes is required.

The FireCLAD® System utilises Boral Plasterboard FireSTOP™, attached to the building frame underneath the Colorbond® steel cladding, to produce fire resistance levels of 60, 90 and 120 minutes from outside fire attack. The FireCLAD® System has been assessed and certified in accordance with the BCA, and independent costing research indicates the system offers substantial construction cost savings when compared with load bearing and non-load bearing precast concrete.

BenefitsThe FireCLAD® System affords the flexibility of using steel structural and cladding components in a very cost effective and attractive system as an alternative to, or in combination with, concrete or masonry construction. FireCLAD® has been used successfully by several pre-engineered industrial building companies.

Good news to both large and small steel framed building fabricators, the FireCLAD® System is also easy to assemble. Pre-assembly and tilt up crane erection, complete with frame and cladding, enables easy FireCLAD® System installation where proximity to adjoining buildings prevents conventional construction methods.

The FireCLAD® System is also ideal for refurbishments and building upgrades. Existing buildings that are adjacent to new construction may be required to have upgraded fire resistance.

This can be achieved using the FireCLAD® System without having to replace the existing steel frame. Remove the cladding, apply the FireSTOP™ Plasterboard and other components, and then replace the cladding for a low cost, fire resistant external wall. The system can also be constructed above a dado height concrete wall whilst still retaining the fire rating. This means that money is only spent on expensive walling where required, not over the whole area, thus minimising building costs.

System Details

The Boral Plasterboard FireCLAD® System comprises a conventional hot or cold rolled steel frame, multiple layers of Boral Plasterboard FireSTOP™ or Wet Area FireSTOP™, membrane, battens, and Colorbond® cladding.

For all heights, the weight of the FireCLAD® System should be supported by the steel frame or reacted through to the floor slab using girt bridging or sag rods. However, for wall heights up to 10 metres high, the weight of the FireCLAD® System may be reacted directly onto the floor slab with the fitting of galvanised mild steel skirting at the base of the wall.

Fire rated details are also available where the FireCLAD® System is penetrated by pipes, cables, ducts and windows, for various treatments at gutters and base of walls, and where control joints or transitions to non fire-rated areas are required.

Note:

• FireCLAD® is registered to Boral Ltd.

• Tyvek® and Homewrap™ are registered to DuPont™.

• Colorbond® and Galvaspan® are registered trademarks of BlueScope® Steel.

FireCLAD® System

3June 2005Boral FireCLAD®

DesignThe FireCLAD® System provides external fire ratings of FRL 60/60/60, FRL 90/90/90 and FRL 120/120/120 as follows:

• FRL 60/60/60 - Two layers of 16mm Boral Plasterboard FireSTOP™ or Wet Area FireSTOP™

• FRL 90/90/90 - Three layers of 13mm Boral Plasterboard FireSTOP™ or Wet Area FireSTOP™

• FRL 120/120/120 - Three layers of 16mm Boral Plasterboard FireSTOP™ or Wet Area FireSTOP™

Note:If in-service conditions of the building are likely to increase plasterboard moisture levels, the use of Boral Plasterboard Wet Area FireSTOP™ is advisable.

System Fire-Rating Description and Physical Data

FireCLAD® 60

(EW1)

1 Hour

FRL60/60/60

Fire-Resistancefrom outside

direction only.

CSIRO OpinionFCO-1555FCO-1890

Boral FireCLAD® Exterior Wall System2 layers 16mm Boral Plasterboard FireSTOP™ or Wet Area FireSTOP™ fixed to girts max. 2.0mm BMT.

Plasterboard Mass 26 kg/m2

2 x 16mm Boral Plasterboard FireSTOP™

or Wet Area FireSTOP™









1½ Hour

FRL90/90/90


direction only.

CSIRO OpinionFCO-1555FCO-1890

2 Hour

FRL120/120/120


direction only.

CSIRO OpinionFCO-1890

FireCLAD® 90

(EW2)

FireCLAD® 120

(EW3)


Details

FireCLAD® System - Perspective View

FireCLAD® System - Typical Vertical Section


FireCLAD® System - Corner Detail

FireCLAD® System - Base of Wall - Skirting Detail

FireCLAD® System - Base of Wall - Dado Wall Detail


Construction DetailsThe FireCLAD® System may be pre-constructed for tilt-up erection by crane/s or applied to suitable wall framing as follows:

1. Girts/framing members should be fixed across or between building column members to provide flat grounds (max. 1200mm centres) for fixing the plasterboard.

2. Angles should be fixed at corners and control joints with Wafer Head Screws at each crossing, crippling where necessary.

3. Fix skirting if required, to girts/framing members at base of wall with wafer head screws at 1200mm max. centres.

4. First layer plasterboard sheets should be cut, fitted with no gaps wider than 1mm between sheet ends or edges and fastened vertically to girts/building framing members with Type D plasterboard screws at 300mm centres along the girt and 200mm centres at sheet ends (10-16mm from sheet edge).

5. Subsequent layers should be fixed with Type L laminating screws at 600 x 600 mm centres in the field and 200mm centres at sheet ends and edges. Alternatively, the second layer may be screwed through the first layer into the girts,providing a cleaner internal finish. Any third layer is then screw laminated to the previous layers as previously described.

6. Stagger all joints between layers a minimum of 200mm.

7. Caulk perimeter and any control joints with an approved fire grade sealant.

8. The FireCLAD® System membrane should be stapled vertically or horizontally in a continuous run over the whole face of the plasterboard to ensure any water is shed outside of the floor slab.

9. Provide additional support to any plasterboard adjacent to penetrations to allow for movement and/or expansion as required. Seal according to Boral Plasterboard details.

10. Screw fix cladding battens through membrane and plasterboard to girts/framing members at centres as required by the building design engineer. Screw fix steel cladding as per cladding manufacturer’s specifications and suitably flash. Fix rainwater guttering and downpipes as normal.

Note:Plasterboard, Membrane and the specified screw fasteners are available through Boral Plasterboard outlets.

Fastener SelectionThe following table shows the correct selection of screws for the construction of Boral Plasterboard FireCLAD® systems.

Construction Details - Upgrade(Where girts are at greater than 1200mm centres)

Where required, existing buildings may have their fire resistance levels upgraded by applying the FireCLAD® System as follows:

1u. Girts/framing members should lie across or between building column members to provide flat grounds (max.2000mm centres) for fixing the plasterboard.

2u. 50x50x0.75mm BMT GMS angle to be placed vertically @ 600mm centres over girts/framing members. Cripple at girt crossings and fasten with one 10x16 DP wafer head screw.

3u. If plasterboard is not supported by concrete, fit shelf angle to slab edge to provide support.

4u. Fix corner angles, control joints and skirting as required to previous details.

5u. First layer plasterboard sheets should be cut and fitted with no gaps wider than 1mm between sheet ends or edges and fastened vertically to girts/building framing members with Type D plasterboard screws at 300mm centres along the angles and girts and 200mm centres at sheet ends (10-16mm from sheet edge).

6u. Subsequent layers, membrane, battens and cladding should be fixed as in points “5” to “10” opposite except that the alternate screw method in “5” should not be used.

FinishingPlasterboard in the FireCLAD® System is overclad and therefore plasterboard joints do not need to be taped or set. If a finish issought on the internal plasterboard wall face, the first plasterboardlayer only may be fixed with its face to the girt/framing system and finished conventionally. Additional layers of plasterboard may also be fixed to the inner face of the framing without downgrading the fire resistance of the system. The plasterboard may then be finished to provide a smooth internal lining.

Screws - Plasterboard to GirtsNumber of LayersPlasterboard x Thickness

Steel FrameType D Screws

1 x 13mm 6 - 18 x 25mm1 x 16mm 6 - 18 x 30mm2 x 13mm 6 - 18 x 40mm2 x 16mm 6 - 18 x 45mm

Screws - Plasterboard to PlasterboardNumber of Layers ofPlasterboard x Thickness Type L Screws for Fixing

Plasterboard A to BPlasterboard A Plasterboard B

1 x 13mm Min 13mm 10 - 8 x 32mm1 x 16mm Min 16mm 10 - 8 x 38mmScrew Identification is given as(min gauge) - (threads/inch±1) x (min length)


Details - Upgrade

FireClad® System - Perspective View - Upgrade

FireClad® System - Base of Wall - Upgrade

Technical Enquiries

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© Copyright Boral Limited 2005The technical information contained in this manual was correct at the time of printing. Building Systems and details are, however, subject to change. To ensure the information you are using is current, Boral recommends you review the latest building information available on the Boral website, contact TecASSIST or your nearest Boral Plasterboard Sales Office.

Fax: (03) 9645 1812 Email: [email protected]

www.boral.com.au

State Sales OfficesACT7 Barrier Street Fyshwick 2609Telephone (02) 6280 4243Facsimile (02) 6280 5816

New South Wales3 Thackeray Street Camellia 2142Telephone (02) 9638 0571Facsimile (02) 9638 5557

Northern TerritoryCnr Coonawarra Rd & Mataram Street(PO Box 38245) Winnellie 0820Telephone (08) 8984 4484Facsimile (08) 8984 3778

Queensland733 Nudgee Road Northgate 4013Telephone (07) 3215 2244Facsimile (07) 3215 2299

South Australia119-121 Bedford Street Gillman 5013Telephone (08) 8240 8888Facsimile (08) 8341 1004

Tasmania93 Albert Road Moonah 7009Telephone (03) 6278 9966Facsimile (03) 6278 9865

Victoria676 Lorimer Street Port Melbourne 3207Telephone (03) 9214 2138Facsimile (03) 9646 1912

Western Australia132 Bannister Road Canning Vale 6155Telephone (08) 9456 0610Facsimile (08) 9455 4377Export Department676 Lorimer Street Port Melbourne 3207Telephone (03) 9214 2138Facsimile (03) 9645 2351

Through TecASSIST Boral Plasterboard is demonstrating its

commitment to providing excellent technical service and support

to design, building and construction professionals Australia wide.

A free-call architectural support line, TecASSIST is available

to provide sound advice on all matters relating to drywall

plasterboard construction.

Combining years of professional experience with the latest design

information and technology, the TecASSIST team has the skills to

help you.

Boral Plasterboard TecASSIST phone line is open to receive

calls from 8:30am to 4:30pm Monday to Friday, Melbourne time

(Victorian public holidays excepted).

GuaranteeProducts manufactured and supplied by Boral Australian Gypsum Limited (BAGL) A.C.N. 004 231 976 (trading as Boral Plasterboard) are guaranteed to be of consistent quality and free from any defects.

Boral Plasterboard may limit its liability under this guarantee to, at its option, the replacement or payment of the cost of replacing OR supplying equivalent or payment of the cost of supplying equivalent OR the repair or payment of the cost of repairing products found to be defective.

Health and SafetyFor information regarding the safe use of Boral Plasterboard products and accessories please refer to instructions on the product packaging or contact your local Boral Plasterboard Sales Office or TecASSIST for a current copy of the Material Safety Data Sheet.

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